December 27, 2022

The process begins by separating household plastic, which is deposited in collection bins outside homes. Plastic bottles are separated straightaway from the metals and other bottles. Colored plastic bottles are separated from transparent bottles. An overview of the process:

Washing: The crushed material is immersed in a washing tank and is dragged towards the end of the system by the water current.

Grinding: After being washed, the plastic is routed to a grinding mill that reduces the size of the material.

Dying: The plastic which has been washed and ground is dried in special ovens with an air stream.

Extrusion: The plastic material is fed into an extruder, transformed into a liquid state and pushed towards a breaker plate whose diameter can vary depending on the type of the structure desired (in our case continuous fibers). When it comes out of the machine, the plastic compound is cooled in water, dried and cut according to needs.

Carding Preparation: The colored wad is sent to the carding preparation department to clean, open and mix the fibers from different bales.

Needling and heat setting: Needling is the mechanical procedure to obtain felt in textile industry. The vertical motion of the needles makes the fiber mattress compact as it leaves the carder. A fairly thick non-woven fabric is obtained due to the penetration of part of the fibers dragged vertically by the movement of the needles. In order to increase the product’s hardiness, finishes like resination and heat setting may be added.

30 Plastic Bottles  2.2lbs of Felt

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